INDUSTRIAL TRAINING REPORT 1 CHAPTRER-1 INTRODUCTION TO CEMENT INDUSTRY IN INDIA Cement industry in India has made significant contribution to the country’s economic development. This is obvious because most of the development activities of the country involve construction works using cement. South Indian Industry Limited installed the first cement industry in Tamil Nadu in 1904 and then onwards number of factories manufacturing cement was started. In our country there are 51 companies and 99 plants having installed capacity of manufacturing 700 million KN of cement and with this installed capacity, the Indian cement industry is the largest in the world after China, Russia, Japan and USA. It accounts of about 4% of the world’s production. Some of the important highlights of Indian cement can be summarised as follows. 1. The energy consumption is substantially higher than that in efficient plants abroad. 2. The energy protection activities require be improving and updating. 3. The new technologies i.e. high efficiency separator, roll press, vertical roller mill, pre calcinators etc, have to be improved. DEPT OF MECHANICAL ENGG RIT KOTTAYAM
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INDUSTRIAL TRAINING REPORT 1
CHAPTRER-1
INTRODUCTION TO CEMENT INDUSTRY IN INDIA
Cement industry in India has made significant contribution to the country’s economic
development. This is obvious because most of the development activities of the country
involve construction works using cement. South Indian Industry Limited installed the first
cement industry in Tamil Nadu in 1904 and then onwards number of factories manufacturing
cement was started. In our country there are 51 companies and 99 plants having installed
capacity of manufacturing 700 million KN of cement and with this installed capacity, the
Indian cement industry is the largest in the world after China, Russia, Japan and USA. It
accounts of about 4% of the world’s production. Some of the important highlights of Indian
cement can be summarised as follows.
1. The energy consumption is substantially higher than that in efficient plants abroad.
2. The energy protection activities require be improving and updating.
3. The new technologies i.e. high efficiency separator, roll press, vertical roller mill, pre
calcinators etc, have to be improved.
4. The requirements such as better packaging materials, bulk containers and ready mix
concrete technology deserve immediate attention.
DEPT OF MECHANICAL ENGG RIT KOTTAYAM
INDUSTRIAL TRAINING REPORT 2
CHAPTER-2
HISTORY OF THE COMPANY
The Travancore Cement Limited was incorporated in the year 1946. The year of
commencement of Grey Cement in the year 1949. The licensed capacity of the plant was
50,800 Ts of cement per annum.
The master-mind behind setting up of this factory was that of late Sir.
C.P.Ramaswami Iyer, the then Devan of Travancore, who had realized the vital role of
cement in the industrial development of Kerala. The company was promoted by M\s. Essel
Limited, Bombay and the Technology tie up made with M\s. F.L.Smith & Co. Denmark.
During 1959, the company diversified into the production of White Portland Cement.
The installed capacity for the production of White Cement is 30,000 Ts per annum. Till 1974,
the company was manufacturing both White Cement and Grey Cement in the same plant,
disturbing the production of two over certain period in a year. Since 1974, the company
manufacturing white Cement alone, as the demand for white cement went up.
During the last 54 years of its existence, TCL has diversified its activities to relate
areas. Besides Super Shelcem brand Cement paint, the company has added to its products
ranges, Sheltex Acrylic Emulsion paint for interiors and exteriors and Shelprime Cement
Primer.
The Travancore Cements Limited is the only manufactured, perhaps in the whole
world, producing White Cement from a raw material other than conventional limestone. The
main raw material of TCL is lime shell, which is dredged out of Vembanad Lake, one of the
back waters in Kerala. The company has successfully executed a diversification project for
manufacture of Grey cement during the year 2000, with a capacity of 66,000 MT per annum.
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CHAPTER-3
DESIGN OF STUDY
3.1 OBJECTIVE OF THE STUDY
To understand the functioning of organization as a whole.
To study the organizational structure.
To study various department of the organization and their function.
To know the organizational objectives and scope.
3.2 SCOPE OF STUDY
The scope of the study conducted includes the study of aims of the company, various
departments and their functions, various products and their production activities, quality
control procedures taken by the company and the work culture of the organization. The study
of the various departments would help in improvement their overall efficiency, by way of
identifying deficiencies.
3.3 METHODOLOGY
This study was conducted by visiting the head office of Travancore Cements Limited
at Kottayam from February 2009 to June 2009. The information’s and data’s were collected
by interacting with the managers, officers and workers and also made interviews. The further
details about the production were taken by the direct observation of the plant process. Also
some of the data’s regarding the past performance of the organization were collected by
referring the annual report of the company.
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CHAPTER-4
PROFILE OF TRAVANCORE CEMENTS LIMITED
4.1 MILESTONES IN THE HISTORY OF TCL
Standard production of Vembanad Grey cement from lime shell in August 1949.
Standard production of Vembanad White cement from lime shell in August 1959.
Grey cement production stopped in 1976.
Diversified into cement paint super shelcem production in 1977.
Celebrate Silver Jubilee in 1982.
Become a government company in April 1989.
Celebrate Golden Jubilee in 1997.
Launched Shelprime Dry Cement primer in January 2000.
Diversified into Acrylic Emulsion Paint Sheltex for interiors and Exteriors in April
2000.
Diversified into Grey cement production from bought outclinker in 2000.
Become an ISO 9002 company in December 2000.
Started HRD centre in 2002. Started production of “Vembanad Wall Putty” in 2008.
TCL has implemented the Quality Management System and maintain best quality
throughout the production process. The row materials are taken by verifying quality and after
and every production process they are testing the quality of sample in the laboratory. Thus
customers are well satisfied with the products
4.2 LOCATION OF TCL
The cement plant is situated on the bank of Kodoor River and on the bank of the state
highway, M.C Road, 4KM away from the town of Kottayam in Kerala. The location of plant
makes it accessible by road as well as by water.
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4.3 BRANCHES AND OFFICES
The company has its registered office and factory at Nattakom, Kerala. Also it has
another registered office in Trivandrum, it has depots at Bangalore, Coimbatore and
Vijayavada.
4.4 PROMOTERS OF THE ORGANIZATION
At first TCL was under the control of private management till 1974 subsequently the
government of Kerala took over the management and now the government holding 50.13% of
the equally share capital. Another 25% of shares are provided by the Pyramid group of
company and the remaining shares are held by General public.
4.5 OBJECTIVES OF THE ORGANIZATION
The main objective of TCL is the production of Vembanad White Portland cement. It
is the first and foremost product of the company. By quality, it is the best whit cement
produced in India. The company is now engaged in the production of cement paint known as
‘Super Shelcem Cement Paint’ which is available in 42 different shades.
4.6 QUALITY CONTROL POLICY
TCL has implemented the Quality Management system and best quality throughout
the production process. The row materials are taken by checking its quality and after each and
every production process they are testing the quality of sample in the laboratory. Thus
customers are well satisfied with the products.
4.7 PROBLEMS FACED BY COMPANY
The main problem faced by the company is the storage of row materials. The
company has serve storage of lime shell which is the major row material for both the products
of the company. The difficulty in commencing mining operations for lime shell in the
company’s lease hold area at Vaduthala is affecting the lime shell availability. The issue is
being sorted out. Now the company is obtained lime shell from ‘Chithira’ lake. The
increasing use of oil and diesel is badly affecting the profitability of the company. Surplus
labour is the another major problem faced by the company.
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4.8 PRODUCTS
The company is producing three types of products. They are,
1. White Portland Cement under the brand name “VEMBANAD”.
2. Cement paints under the brand name “SUPER SHELSEM” in 42 different shades.
3. Wall putty under the brand name “VEMBANAD”.
1. VEMBANAD WHITE PORTALAND CEMENT
It is the first place in Indian white cement market by its excellent quality and its
quality is at pas with that of the best available in the world market. As compared to others
brand it accounts for its superior whiteness and maintain its quality by using lime shells
instead of lime stone. The white cement is the best suited for housing and construction of
industries. Vembanad White Cement is quickly drying, process high strength and superior
aesthetic values. Also it is good for floor finish, plaster and ornamental works. The
miscellaneous application of white cement are in swimming pools, where it replaces the use
of glazed tiles with coloured shades under water, for moulding sculptures and statues, for
painting furniture’s. It is also used for ready mixed concrete and precast blocks and also
fixing marbles and glazed tiles. Today the company enjoys the highest 8042 e-1976
specification.
SPECIAL FEATURES
Lowest magnetic content and hence most durable white cement.
Brilliant whiteness.
High strength.
Super soundness.
Super finishing.
Excellent properties.
Ideal for manufacturing cement paints, mosaic tiles etc.
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APPLICATIONS
Pointing brick works.
Road marking.
Cast stone finish.
External rendering.
Mosaic tiles.
Terrazzo flooring.
Primary coat for cement paints.
2. SUPER SHELCUM CEMENT PAINT
In 1977 TCL started manufacturing cement paints under the brand name
“SHELCEM”. It was rebranded as “SUPER SHELCEM” in 1986. Super Shelcem is a unique
technology formulation with the most durable “VEMBANAD” white cement. It is an
intimate mixture of Vembanad white cement, water proofing fungicides, oxide extends, non
fading oxide pigments and hardening agents. Cement paint is water biased paint widely used
for painting buildings.
Unlike other cement paints, Super Shelcem doesn’t require water curing after first and
second coat. Only initial wetting of the surface is necessary. This makes it ideal for exteriors
of multi storied buildings and sky scrapers. Also it is ideal for interiors since, tedious curing
after removing furniture can be avoided which means saving of labour. Once a wall is painted
with Super Shelsem , it looks and stays good for years un affected by weather and fungal
attack .
Super Shelsem carries ISI marks and the approval of Bureau of Indian Standards, is
E-1969. It is available in a wide range of colours of total 42 different shades in the market.
SPECIAL FEATURES
CAPACITY: Any previous deep shade made on the surface can be effectively
hidden with a single coat of Super Shelcem. The second coat completely covers the
dark patches and stains on the wall.
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COVERAGE: Super Shelcem covers greater area than any other cement paint. 1Kg
covers 100 sq feet for a single coat or 65 sq feet for two coats.
ADHESION: Super Shelcem can be applied on a wide variety of surface like
cement plaster, concrete, brick work and plastered surface.
DRYING: Super Shelcem dries very quickly. While other cements paints requires
16 to 24 hours waiting time for applying the second coat, Super Shelcem need only
3 to 6 hours after the first coat.
3. VEMBANAD WALL PUTTY
Vembanad Wall Putty was introduced in the last year, i.e. in 2008. It is dry powder
putty with Vembanad White Cement as the base. By the low content of MgO in Vembanad
White Cement, the putty when applied on the cement plastered wall and ceiling will ensure
durability, extra coverage and smooth finish. Vembanad Wall Putty can be applied on
freshly plastered surface also.
Like other products of TCL, Vembanad Wall Putty is also excellent in quality.
Before applying wall putty, one or two coats of Vembanad White Cement is recommended
to be applied on the newly plastered wall.
SPECIAL FEATURES
Quality tested Vembanad White cement is used for making wall putty.
Its production process goes through the strictest quality test.
It has a unique formulation.
It has more coverage than any other wall putty in the market.
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CHAPTER-5
ORGANIZATION STRUCTURE
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The Board Directors consists of five persons of which one is full time Managing
Director. Under the General Manager there are five Chief Managers, i.e. for Finance,
Personal, Production maintenance, Marketing and Purchase. The maintenance manager is
responsible for departments of dredger, civil and sanitary, water and general transport,
workshop and electrical. The production manager is responsible for the departments of white
cement plant, kilin, packing house, shelcem, lab and quality control. The purchase manager is
responsible for the departments of purchase, stores and shelcem. The finance manager is
responsible for the departments of accounts. Finally the personal manager is responsible for
the time office, personal department, office and guest house.
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CHAPTER-6
PERSONNEL DEPARTMENT
DEPARTMENT STRUCTURE
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It is the department which is connected to other departments in TCL. This department is
headed by Joint General Manager. Under him Joint Chief Manager followed by Junior
Executive and office assistance. The recruitment and selection of the personnel are owned by
this department. Another important function of personnel department is to loot into welfare of
its employees. Time office comes under this department. The function of time office is to
maintain leave register, attendance making, overtime confirmation etc. The above data is
forwarded to the accounts department for accounting the wages of employees.
1. EMPLOYEE POTENTIAL
In TCL are totally 595 employees, which include 24 officers. The officers of the TCL are
further classified into:
General Manager
Manager Grade
Special Grade
Class one Grade
Class two Grade
People working in the office, a security and a senior employee in the plant come under the
staff category. The grade of staff varies from 1 to 7. It being the lowest grade and 7 being
highest grade. Workers in TCL are classified into:
1. Permanent
2. Probation
3. Temporary
4. Casual
5. Apprentice
The grades of workers vary from A to E. E being the lowest grade A being highest.
1. TIMING
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The office time of TCL is from 9 am to 5 pm. On Sundays the working time is from 9 am to 1
pm. The factory is working on the shift basis.
1. 3 continuous shift of 5 hours each
2. 2 special shift to 8 hours each
3. Special shift for special work of 8 hours
4. A general shift of 8 hours
3. MAN POWER PLANNING
Man power planning is a key economic resource of an organization. Man power planning is
the process by which a firm ensures that it has right number and right kind of peoples at right
places.
Man power planning includes a series of activities consisting of the following:
1. Forecasting
2. Anticipating man power status
3. Planning
4. SALARY AND WAGES
Salary and wages to be paid to the employees are determined on an agreement between CMI
and Trade Union. In TCL pay revision is done by every 4 years.
5. LEAVE PATTERN
There are 14 days of casual leave and 12 days of sick leave. For non-staff workers 18 days
of privilege leave are allowed and for officers 30 days.
6. RECRUITMENT AND SELECTION
Recruitments is done through direct application and through employment exchange.
Selection is mainly based on written test and interview. Selected person will have undergo a
period of training. The training period is usually six months and for higher post it may
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extended to one year or more. Every worker is liable to be transferred from one department
to another and one job to another according to experience of work in the factory.
7. TRADE UNIONS
The recognized trade union. In the company are:
1. Travancore Cements Workers Union
2. Kerala Cement Workers Union
3. Travancore Workers Union
4. The Kottayam Cement Workers Union
8. CANTEEN
A fare price canteen is operating at the premises. The employees are given Rs. 30 per day of
attendance. Maximum Rs.900 per month is allowed by the company.
9. WELFARE FACILITIES PROVIDED BY THE COMPANY
Uniform 3 pairs of uniform once in two years
Foot wear allowance Every year
Umbrella Once in two years
Rain coat Once in three years
Washing soap Two half bars in a month
Toilet soap Two numbers in a month
Turkey towel Every year
10. COMPANY SCHOLARSHIP
Company is giving scholarship to the children of employees.
For S.S.L.C, P.D.C, to Degree & Diploma
Rs. 700/- for 1st highest rank. Rs 500/- for 2nd rank.
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12. DEATH BENIFIT
Rs. 5000/- will be given to the department of the deceased employee to meet the expenses
in connection with funeral.
13. TOUR
Inside Kerala and outside Kerala
For staff and officers- one in an year
For workers-Two each
14. TRANSPORTATION
Free transportation facility provided to employees for coming and return after duty. For the
children of employees for attending education institution in and around Kottayam.
15. FACTORY DAY COMPLIMENT
Every year
16. SPECIAL ADVANCE
For medical treatment up to maximum Rs. 15000/- is allowed for all members and for
marriage expense up to maximum Rs. 25000/- is allowed.
17. LOAN SCHEME
Two wheeler/cycle loan is allowed for all employees and car/computer loan is allowed for
all officers.
18. COMPANY’S PPRODUCT AT CONCESSIONAL RATE
Super shelcem cement paint and Emulsion paint are sold to employees at factory gate price.
19. QUARTERS FACILITY
A limited number of employees are provided with quarters with free electricity and water.
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20. RECREATION FACILITY
Recreation facility for indoor games, reading rooms with newspaper and periodicals, T.V
with cable facility.
21. TRAINING AND DEVELOPNENT
There are both internal and external training for workers and employees, and it is
conducted by the HRD centre under the supervision of the Personnel Development. Job
rotation is allowed only for officers. Conference, talks, workshops, etc. Are conducted as
part of training and development.
22. WELFARE FUND SUBSCRIPTION
Company is contributing Rs. 10/- per member towards monthly subscription.
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CHAPTER 7
PURCHASE DEPARTMENT
DEPARTMENT STRACTURE
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The purchase and store department plays an important role in the proper functioning of the
entire organization. This department comes under the material management. It has a
common department head and he look after all the activities relating to raw materials and
other general consumer thing.
ADVANTAGES OF PURCHASE DEPARTMENT IN TCL
1. Because of centralized purchasing of materials, favourable terms, eg. Trade
discounts or economic in transportations can be obtained because quality will be
large.
2. The purchasing department can be staffed with highly paid officials who are experts
in the art of purchasing the materials. Specialized knowledge and skill of this
persons can be utilized.
3. All records with regard to purchase are kept at one place under the supervision of
the purchase officer.
4. Helps in achieving following uniform purchasing policies, practices and procedures.
5. It avoids duplication of efforts and is helpful in achieving standard products.
1. FUNCTIONS OF PURCHASE DEPARTMENT IN TCL
The main functions of purchase department are
Placing order
Inviting quotations
Correspondence
Following steps are taken to perform the above functions
STEP 1: Purchase requisitions or indenting for materials
The purchase officer does not initiate any action for purchase of materials on his own
record. With the help of purchase requisitions the purchase officer come to know the types
of materials needed by the organization. A purchase requisition is a formal request for the
purchasing department to purchase materials.
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STEP 2: Exploring the sources of supply and selection the supplier
A source of supply materials is to be selected after the receipt of purchase requisition. In
TCL, the process of choosing the supplier is not a hard task. The shopkeeper generally
mentions the name of the current suppliers, their price quotations, and the purchase
department also has a series of good suppliers. Choosing the right supplier from the
suppliers list involves a process of comparative statement of purchases. It is a statement
prepared by the purchase department.
STEP 3: Purchasing order
After choosing the supplier, the purchase department prepares order of the supply of sores.
The order is a written authorization to the supplier to supply the particular material or
materials. It is the evidence between the buyer and the supplier having the terms and
conditions of the purchasing order.
STEP 4: Receiving and inspecting materials
In large concerns, a separate Receipt and Inspection department independent of stocking
location should be set up to receive and inspect the materials. But in small concerns this
work is done by the stock keeper. In TCL, the stores department makes the general
purchase only. This contains 22 classes of items needed for various consumable
departments. When goods are received in stores the consuming department is informed and
the personnel’s form this department come to stores and inspect the quality etc.
STEP 5: Checking and passing bills of changes
After checking the bills are passed. Generally the payment terms of TCL are,
Against invoice or acceptance of stock a minimum 15 days credit.
In case of monopoly suppliers, they are sent/paid through banks.
2. CONDITIONS REGARDING RECEIPT OF GOODS
If the suppliers are within Kerala a time within 15 days of sending/inviting
quotations.
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If supplies are outside Kerala a period within 20 to 30 days
The company makes local purchase itself within 2 to 3 days.
3. PURCHASE LIMITS
In TCL, they followed an authorized purchasing system. The purchase units are as follows
1) Below and up to Rs.5000, purchases are maintained by Junior Manager and
sanctioned by Chief Manager Purchase in charge.
2) Rs.5000 to Rs100000, Chief Manager should sanction it.
3) Rs.100000 to 5000000, it should be signed and approved by Managing Director.
4) Rs.5000000 and above, approved by sub Committee/Board of Directors.
4. STORE LOCATION LAYOUT
The location of stores department could be carefully planned out and it should be housed
in a position which is very near to receiving department so that transportation charges at a
minimum. In TCL, stores department is very near to the consumable department.
5. STOCK LEAVEL
In stores, items are divided into three levels namely
1) Maximum level
This represents the maximum quality of materials which must be maintained in
hand at all items. While fixing this level, TCL considers following facts
Rate of consumption of materials.
Amount of capital available.
Storage space of available.
Cost of maintaining store.
Risk of obsolescence.
Re-Order quantity.
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2) Minimum level
This represents the minimum quantity of materials which must be maintained in
hand at all items. This quantity is so fixed that the production may not be held up due to
shortage of materials. While fixing this level, TCL considers the following.
Normal rate of material consumption.\
Lead time.
Re-Order level.
3) Re-Order level
It is the point at which the stock of particular material reaches the re-order quantity.
The storekeeper should invite the purchase requisition for fresh suppliers of that material.
While fixing this leave TCL considers following factors,
Maximum delivery time
Maximum rate of consumption
Minimum level
6. FUNCTION OF STORE KEEPER
One of the duties of the store keeper is to send requisition for materials for replenishment
in time so that the production may not hamper for want of materials. The store keeper
requisites the items need which are generally depending on the consumption pattern of
various departments.
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7. ADVANTAGES OF CENTRALIZED STORES
1. Better control can be exercised over stores because all stores are housed in
one department.
2. Better layout of stores is possible.
3. Investment in stock is minimized.
4. Economy in cosy
5. Economy in staff and concentration of experts in one department will leda
to development in high technical skill.
6. Less botherisation Inventory checking are required,
8. STORES RECORD
The Bin card and Karde-X card are the two important stock records that are kept in TCL
for making a record of various stores.
9. BIN CARD
A bin card makes a record of the receipts and issue of materials and is kept for each item
of stores carries. Quantity of stores received are entered in the receipt of stocks are
recorded in the issue column of the bin card is usually hangs up or placed in shelf, rack,
or bin where the materials have been kept.
10. KARDE-X CARD
This card is used in TCL by store keeper in addition to the bin cards for storing list of
stock of items.
TCL does not maintain a store ledger, instead of this all the details are stored using
software in computer. The existing system is a FoxPro biased system.
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CHAPTER 8
PRODUCTION DEPARTMENT
DEPARTMENT STRACTURE
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The production and service department control and coordinate the production process can
be mainly divided into three stage; they are slurry preparation, clinker making, and clinker
grinding. The total numbers of workers in these three stages are 75 with 17 employees in a
shift.
1. PROCESS OF MANUFACTURING
The two main process of Travancore Cements Ltd. Are Vembanad White Portland Cement
and Super Shelcem Cement Paint. Here we are discussing the manufacturing of Vembanad
White Cement and Super Shelcem Cement Paint.
The TCL produces Vembanad White Cement using the Rotary kiln and wet process
technology which is patented by F.L Smidth and company Denmark.
2. RAW MATERIALS
Vembanad White Cement is manufacturing from natures gift of rare raw materials which
are unique in consistent purity. The company is using high quality raw materials and wet
process in order to maintain the quality of its products. The main raw materials are lime
shell, white clay, white sand and Crystal gypsum.
a. LIME SHELL
Lime shells are found as under water depots in the Vembanad lake. Chemical analysis of
lime shells reveals that almost 99% accounts for calcium carbonate (CaCo3). While the
presence of usual impurities like iron and magnesium compounds are negligibly
insignificant.
Vembanad white cement has the distinctive feature of being only cement that is
manufactured form lime shell.
b. WHITE CLAY
white clay are crude china clay is obtained from southern parts of Kerala, particularly from
Trivandrum district. These white clay depots of Southern Kerala are famous for their purity
and high ceramic properties. The milky white clay, which is in paste form, go into the
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manufacturing process of Vembanad White Cement, is almost 85% pure Hydrated
Aluminium Silicate.
c. WHITE CLAY
The white sand is obtained from the coastal areas of Chertala in Kerala, which is accounts
of purity up to 95%.
d. CRYSTAL GYPSM
PRODUCTION PROCESS OF VEMBANAND WHITE CEMENT
The basic cement making process consist of collecting the row materials, grinding them to
a fine stage, blending them to a uniform composition and heating them to the point of
sufficient fusion when the cement compounds are formed. Portland cement is the product
obtained by cooling and grinding the clinker thus formed with gypsum to a fine powder.
Production process can be mainly divided into three stages:
Slurry preparation
Clinker making
Clinker grinding
The different processes under these main stages are:
1. Dredging
2. Unloading station
3. Wash mill
4. Shell-sand grinding(Ball mill)
5. Slurry making(Raw mill)
6. Slurry section
7. Clinker making(Kiln)
8. Clinker grinding(Cement mills)
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1. DREDGING
The main raw material for the production of Vembanad White Cement is lime shell an
underwater deposit in Vembanad Lake, is dredge and brought and brought to the company
by means of power bargers.
The company has two dredgers, one hydraulic dredger and one mechanical dredger. The
capacity of two dredgers may about 30 tonnes/hour. The dredger can cut the lime shell
around 40 feet maximum depth. The dredger works on two powerful engines, a dredger
pamper engine and an auxiliary engine.
2. UNLOADING STATION
The shell brought by Barger from lake is unloaded here. Shell in barger is diluted with
about 60% of water by means of diluting pump for easiness of sucking. A sucking pump
draws water along with the shell to receiving tank near the rotary grill of screening plant.
The shell is then passed through the rotary grill and waste materials are washed out during
its rotation. Cleaned shell is either passed through the belt conveyors through hoppers or
stored out. There are two rubber conveyors (Conveyor 1-short and straight, conveyor 2-
long and inclined) for conveying the shell to the ball
3. WASH MILL
Before actually used for the process clay is mixed with water. This work is done in a clay
wash mill. Clay is put into the mill and about 65% of water is also added during the
grinding. During the hammering action of the weights provided in the wash mill clay is
made to slurry is pumped to the storage tank known as silo. From silo, it is taken for
process when required.
4. SHELL-SAND GRINDING
Slurry preparation is the fourth stage in the production process of whit cement. Slurry is a
mixture of shell, sand and clay with around of 40% of water.
For slurry preparation two grinding mills are used:
Roughing mill known as ball mill
Finishing mill known as row mill
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Ball mill is a cylindrical shell of welded metal plates.
The shell around required amount of white sand and water is fed to the ball mill by rotating
feed table. When the mill rotates the materials are crushed down to the small particulars while
it passes through the ball. The materials coming out of the ball mill is diverted to a hammer
screen by means of slurry elevator. Fine material come out of the hammer screen is fed to the
row mill. The coarse material return to the ball mill for further grinding.
5. SLURRY MAKING
The row mill is hollow cylindrical shell, the inside of which is line with flint blocks. The
shell lining are avoided to reduce the contamination of slurry by iron. The grinding media is
used is Flint Pebbles. The mill is rotated by a motor at constant speed while passing through
the mill, the fine materials discharged from ball mill and clay pumped from clay silo are
finally ground and comes out as a party material known as slurry which then flows to slurry
pit.
6. SLURRY SECTION
Slurry discharged from the row mill is stored in silos by means of pipes. The chemical
composition of the slurry will be adjusted by this stage. There are three silos for storing the
slurry. From these silos slurry is pumped to the slurry basin. In the basin slurry is constantly
agitated with compressed air and stirring mechanism. From the basin, slurry is taken from
burning in the kiln.
7. CLINKER MAKING
kiln is a cylindrical steel lined with refractory bricks mounted at an inclination of 30˚ on
roller supports. The kiln having a length of 285 feet with diameter of about 9 feet and is
rotated at about 1rpm by an electric motor.
During the process of slurry passes through three stages:
1. Drying zone
2. Calcinations zone
3. Burning zone
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In the drying zone about 99% of water content in the slurry will removed. In the calcinations
zone the removal of CO2 take place. After that the materials enters the burning zone. The
clinker is formed in the burning stage by fusing Diclacium Silicate, Tricalcium silicate, and
Tera calcium Alumino Ferrite at about 400˚ C. There after the clinker is cooled by flow of
air. Clinker come out of the cooler will be usually in the modular form.
8. CILNKER GRINDING
The cooled clinker is grinded is very finely to make white cement. Clinker grinding take
place in the cement mill. There are cement mill A,B&C with clinker grinding capacity of 60
tonnes, 50 tonnes, 50 tonnes respectively. The mills B&C are identical in nature. During
grinding, small quantity about 3% to 4% Gypsum is added. The Gypsum controls the initial
setting time of cement. If gypsum is not added, the cement wouldn’t set as water is added.
The gypsum act as retarder and it delays the setting action of cement. It thus permits cement
to be mixed with aggregate and to be placed in the position. The cement coming out of the
mill is conveyed to claufies by means of bucket elevator. In the separator, causes particles are
separated and they flow to the mill while fine particles flow to the Flaxo pump, which is
operated by compressing air. Using Flaxo pump cement is transferred to the cement silo
located at the packing house.
9. PACKING AND DISPATCHING
The white cement stored in silos is packed in paper bags in the packing house. Compressed
air is used for the free flow of the cement from the Silo and hopper located above the packing
machine. While the bag is filled with 50Kg materials discharges from the spout is
automatically transferred to truck through a fixed point belt conveyer and a movable belt
conveyer. The filled bags fall down from the spout to the wire net conveyor and are
transferred to truck through a fixed point belt conveyer and a movable belt conveyer .
CEMENT PAINT DEPARTMENT
Paint is a surface coating which decorates and protects the surface on which it is applied.
Paint is a mixture of four elements they are:
1. Solvents
2. Binders
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3. Pigments
4. Additives
The total paint market is broadly categorized into four segments: